Capacity Utilization Analysis

A manufacturing plant $pr2$oduces electronic components for industrial machines.

The plant operates $22$ working days per month. $At$ full capacity, $it$ produces

$140$ units per day.

During a recent month, the plant produced $2,600$ units. Due $to$ maintenance

and supply delays, the production time was reduced.

Task:

Calculate the capacity utilization percentage for the month.

Given:

Scheduled working days $=22$ days

Maximum units per day $=140$ units

Actual units produced $=2,600$ units

Formula:

Capacity Utilization $(\%)=(\frac{\text{A}\text{c}\text{t}\text{u}\text{a}\text{l}\text{O}\text{u}\text{t}\text{p}\text{u}\text{t}}{\text{M}\text{a}\text{x}\text{i}\text{m}\text{u}\text{m}\text{P}\text{o}\text{s}\text{s}\text{i}\text{b}\text{l}\text{e}\text{O}\text{u}\text{t}\text{p}\text{u}\text{t}})100$

where

Maximum Possible Output $=$ Scheduled days $$Max units $\frac{?}{?}$ day Average Inventory Level Calculation

A company orders $200$ units $of$ a spare part each time $it$ replenishes inventory.

The annual demand for the part $is1,200$ units.

Task:

Calculate the average inventory level the company holds over the year.

Given:

Annual demand $(D)=1,200$ units

Order quantity $(Q)=200$ units

Formula:

Average Inventory $=\frac{Q}{2}$

Production Cycle Time

A factory produces metal sheets. Each production run produces $500$ sheets

and takes $8$ hours. After each run, the machine requires $2$ hours $of$ setup

before starting the next run.

Task: Task:

Calculate the production cycle time for one run including setup.

Given:

Production run time $=8$ hours

Setup time $=2$ hours

Formula:

Production Cycle Time $=$ Production Run Time $+$ Setup Time

Labor Productivity

$An$ assembly line produces $900$ units per $8-$hour shift using $15$ workers.

Task:

Calculate the labor productivity $in$ units per worker per hour.

Given:

Total units produced $=900$ units

Shift length $=8$ hours Number $of$ workers $=15$

Formula:

Labor Productivity $=\frac{\text{T}\text{o}\text{t}\text{a}\text{l}\text{u}\text{n}\text{i}\text{t}\text{s}\text{p}\text{r}\text{o}\text{d}\text{u}\text{c}\text{e}\text{d}}{\text{N}\text{u}\text{m}\text{b}\text{e}\text{r}of\text{w}\text{o}\text{r}\text{k}\text{e}\text{r}\text{s}\text{H}\text{o}\text{u}\text{r}\text{s}\text{w}\text{o}\text{r}\text{k}\text{e}\text{d}}$

Machine Utilization Process Flowchart$(Draw$ Flowchart$)$

A manufacturing facility's machine $is$ available for production $10$ hours per day.

The machine's actual run time varies due $to$ setup, maintenance, and downtime.

Management wants $to$ understand the process $of$ measuring and reporting

machine utilization.

Task:

Draw a process flowchart showing the steps involved $in$ tracking machine

utilization for a typical day. The flowchart should include:

Start $of$ the day and machine availability check

Recording available machine hours

Recording actual machine run time

Logging downtime reasons $(e.g.,$ setup, maintenance, breakdown$)$

Calculating and reporting utilization $(as$ a process step, $no$ math neede

$d)$

End $of$ process

Operation management $!!$